Gear driven direct differential cross

Abstract

A drive axle assembly is provided in which the differential cross-shaft supporting the differential gears is driven directly by the ring gear. The assembly reduces loading on the differential case to which the ring gear is attached thereby enabling the use of low capacity joints between the ring gear and differential case and/or a lighter differential case.

1. A drive axle assembly, comprising:
 a drive axle housing; 
 an input shaft disposed within said housing about an axis of rotation; 
 a pinion gear driven by said input shaft; 
 a differential case supported for rotation within said drive axle housing, said differential case including first and second members configured to receive first and second side gears and first and second axle half shafts, respectively, said first member of said differential case including a ring gear in engagement with said pinion gear and defining a first shoulder, said first and second members of said differential case defining a second shoulder opposing said first shoulder at an intersection of said first and second members of said differential case; 
 a plurality of differential gears supported for rotation within said differential case and in engagement with said first and second side gears; and, 
 a differential cross-shaft supporting said plurality of differential gears, said differential cross-shaft supported between said first and second shoulders 
 wherein said first shoulder is formed by first and second surfaces of said first member extending generally perpendicular to one another and forming a first corner and said second shoulder is formed by said second surface of said first member and a first surface of said second member extending generally perpendicular to one another and forming a second corner, said differential cross-shaft engaging said first and second corners. 
 
     
     
       2. The drive axle assembly of  claim 1 , wherein a diameter of said cross-shaft is uniform from one longitudinal end to an opposite longitudinal end. 
     
     
       3. The drive axle assembly of  claim 1  wherein said first member of said differential case is unitary in construction. 
     
     
       4. The drive axle assembly of  claim 3  wherein said first member is supported for rotation within said drive axle housing by a set of bearings. 
     
     
       5. A drive axle assembly, comprising:
 a drive axle housing; 
 an input shaft disposed within said housing about an axis of rotation; 
 a pinion gear driven by said input shaft; 
 a differential case supported for rotation within said drive axle housing, said differential case including first and second members configured to receive first and second side gears and first and second axle half shafts, respectively, said first member of said differential case including a ring gear in engagement with said pinion gear and defining a first shoulder, said first and second members of said differential case defining a second shoulder opposing said first shoulder at an intersection of said first and second members of said differential case; 
 a plurality of differential gears supported for rotation within said differential case and in engagement with said first and second side gears; and, 
 a differential cross-shaft supporting said plurality of differential gears, said differential cross-shaft supported between said first and second shoulders 
 wherein said differential cross-shaft has first, second, third and fourth circumferentially spaced flats, said first member of said differential case engaging said first, second and third flats and said second member of said differential case engaging said fourth flat.